hi all checked over connections and everything seems to be okay, nothing obvious except for the starter relay melting.
took it for a quick run around the block and it started to visibly melt more.

Have ordered a new starter relay of ebay and will try and fit it to the bike, but it looks as if I am going to have to butcher the old one to get the new one on, and I need a new block connector for the loom side if anyone knows of where I can get one that would be brilliant

I might have something on an old loom I have in the garage, pop up a picture of what you need and I'll look tonight.

For future reference you can get the starter motor solenoid connector block from towzatronics on ebay http://www.ebay.co.uk/itm/290565229834? ... 3D1&_rdc=1

brido wrote:hi all checked over connections and everything seems to be okay, nothing obvious except for the starter relay melting.
took it for a quick run around the block and it started to visibly melt more.

Have ordered a new starter relay of ebay and will try and fit it to the bike, but it looks as if I am going to have to butcher the old one to get the new one on, and I need a new block connector for the loom side if anyone knows of where I can get one that would be brilliant

Did you clean up the fuse conections througly? and replace the fuse (could have bad connections)

Some fuses are slightly thinner.

A poor fitting fuse and / or corroded / dirty connections will cause more resistance.. this generates excessive heat as the current tries to overcome this.. then your plug melts.

This is why the yellow-wire plug from the alternator melts often.. it gets corrded up and the extra heat burns it up

Hi neo wasn't able to clean any connections as the fuse holder had melted to the starter relay and until I was able to get a new connector block I wasn't going to try and break them apart, I have now got a block from a place called towzatronics on ebay. So when I get some time I will replace the lot and see what happens, hopefully this cures it.

Okay update on the melting problem, I have got the starter relay replaced with a new one and a new connector block replaced onto the loom side of things, everything wired up, plugged in and running. Just need to take it for a run, so weather permitting next monday or tuesday. Will update on how things go.

brido wrote:For future reference you can get the starter motor solenoid connector block from towzatronics on ebay http://www.ebay.co.uk/itm/290565229834? ... 3D1&_rdc=1

Well how about that... I didn't know you could get these...
Saves on the cost of a new solenoid every time...